A high-pressure abrasive water jet collaborative cutting control system and control method

Abstract

The application discloses a high-pressure abrasive water jet cutting control system and a control method thereof. The system comprises: a multi-source sensing layer for acquiring flow field information, rock response information and equipment state information during high-pressure abrasive water jet cutting; a data processing and control core layer for processing collected data, extracting features, calculating frequency matching, making optimization decisions and outputting parameters; a human-computer interaction and visualization layer for realizing parameter setting, state monitoring and data output; a control instruction output layer for generating execution control instructions according to optimization results; an execution mechanism layer for executing cutting control parameter adjustment and completing the cutting process; and a feedback closed loop layer for feeding back cutting results and system operation states and correcting control parameters. Compared with a traditional control system, the control system has the advantages of 20-50% increase in cutting efficiency, 15-40% reduction in unit energy consumption, 30-80% increase in nozzle service life and improved adaptability to complex rock layers.

Description

Technical Field

[0001] This invention relates to the field of high-pressure water jet rock breaking technology, and in particular to a high-pressure abrasive water jet collaborative cutting control system and control method based on the coupling of flow field feedback and rock response. Background Technology

[0002] Existing high-pressure abrasive waterjet cutting processes typically employ fixed-parameter control, which cannot adjust operating parameters in real time according to changes in the flow field and rock response. This results in problems such as low cutting efficiency, high energy consumption, severe nozzle wear, and poor adaptability to different rock types. Therefore, a collaborative cutting control system that integrates flow field monitoring, rock response monitoring, and feedback control is needed. Summary of the Invention

[0003] To address the shortcomings of the existing technologies, this invention provides a high-pressure abrasive waterjet synergistic cutting control system and method that dynamically adjusts cutting parameters, matches the jet frequency with the rock response frequency, compensates for nozzle wear, and improves cutting efficiency.

[0004] To solve the above-mentioned technical problems, the present invention adopts the following technical solution:

[0005] A high-pressure abrasive waterjet collaborative cutting control system includes: a multi-source sensing layer for acquiring flow field information, rock response information, and equipment status information during the high-pressure abrasive waterjet cutting process; a data processing and control core layer for processing the acquired data, extracting features, calculating frequency matching, making optimization decisions, and outputting parameters; a human-machine interaction and visualization layer for setting parameters, monitoring status, and outputting data; a control command output layer for generating execution control commands based on the optimization results; an actuator layer for adjusting cutting control parameters and completing the cutting process; and a feedback closed-loop layer for providing feedback on the cutting results and system operating status and correcting control parameters. The multi-source sensing layer is connected to the data processing and control core layer, which is connected to both the control command output layer and the human-machine interaction and visualization layer. The control command output layer is connected to the actuator layer, and the feedback closed-loop layer and the data processing and control core layer form a closed-loop control.

[0006] This invention also provides a high-pressure abrasive waterjet coordinated cutting control method, which employs the aforementioned high-pressure abrasive waterjet coordinated cutting control system; the control method includes the following steps:

[0007] Step S1: The multi-source sensing layer acquires flow field, rock response, and equipment status information; in this step, the multi-source sensing layer is responsible for simultaneously acquiring jet, rock response, and nozzle equipment status information; the flow field acquisition module obtains the nozzle outlet pressure. oscillating cavity pulsation signal Abrasive flow rate and abrasive concentration The rock response acquisition module acquires rock vibration signals. Acoustic emission signals Crack displacement and cutting depth Nozzle wear monitoring device measures real-time outlet diameter. And calculate wear parameters The rotation angle sensor records the nozzle rotation angle. Rotation speed and cutting feed speed All signals are sampled synchronously using a unified clock to provide a complete input vector for subsequent processing.

[0008] Step S2: The data processing layer performs filtering, feature extraction, and state recognition; in this step, the data processing unit preprocesses the various acquired signals; pressure signal and oscillating pulsation After bandpass filtering (200Hz–10kHz), the vibration signal Harmony emission signal The signal also undergoes appropriate filtering; subsequently, a Fast Fourier Transform (FFT) is performed on the processed signal to extract the main frequency: jet main frequency. and rock response frequency The crack propagation rate is determined by The calculations are performed; finally, the features are combined to form a state vector. , as input to the matching and evaluation unit;

[0009] Step S3: Establish and evaluate frequency matching relationships; in this step, the matching and evaluation units calculate the frequency matching coefficients. And compare it with the preset locking range (0.8–1.2); based on the current nozzle wear parameters and wear rate Calculate the wear impact factor, and combine it with the real-time cutting depth. Forming a comprehensive evaluation function This is used to determine whether optimization control is triggered; if Not in the locked range, or Exceeding the threshold The system will then enter the control and adjustment phase;

[0010] Step S4: Optimize the algorithm to generate control parameters. The decision-making and optimization unit performs phased optimization control based on the evaluation results of step S3; the phase division is based on the crack propagation rate. Harmony emission characteristic parameters The stage is categorized as: initial intrusion stage, crack propagation stage, or stable cutting stage; the control objectives differ for each stage: increasing pressure in the initial stage. And reduce the feed rate Increase pulse frequency during crack propagation stage And optimize nozzle rotation angle During the stable phase, energy consumption should be reduced as a priority. And maintain stable cutting; optimize the results to generate control vectors. , as the input to the control output layer;

[0011] Step S5: The control command output layer controls the actuator; the control output layer receives the optimized control vector. Each instruction is mapped to a specific actuator: the high-pressure pump regulates the pressure. Abrasive valve for flow regulation 1. Adjusting the pulse frequency of the oscillation driver Servo mechanism adjusts nozzle angle Adjusting the feed platform speed The actuator layer precisely adjusts the injection state according to the control vector to achieve real-time cutting operation.

[0012] Step S6: The feedback layer collects the cutting results and corrects the parameters; during execution, the feedback closed-loop layer monitors the cutting depth in real time. kerf width and nozzle wear rate By calculating the cutting error , For the target cutting depth, This represents the actual cutting depth, excluding cutting error. If the error exceeds the preset tolerance (e.g., 5%), the system will feed back to the data processing and control core layer to recalculate the frequency matching, wear compensation, and stage control optimization to ensure cutting quality and system stability.

[0013] Step S7: By cyclically executing steps S1–S6, the system forms a continuous closed-loop control. Each iteration uses the latest collected flow field, rock response, and equipment status data for calculation, enabling frequency locking, wear compensation, and stage control strategies to work together to achieve high-efficiency, high-stability, and long-life high-pressure abrasive waterjet cutting control.

[0014] By adopting the above technical solution, the present invention has the following technical effects:

[0015] (1) Compared with the traditional control system, the high-pressure abrasive water jet collaborative cutting control system of the present invention has the following advantages: cutting efficiency is increased by 20-50%; unit energy consumption is reduced by 15-40%; nozzle life is increased by 30-80%; and adaptability to complex rock formations is improved.

[0016] Improving cutting efficiency: A dynamic matching mechanism between the jet pulse frequency and the rock response frequency was established. By real-time acquisition of jet pressure signals, pulsation signals, and rock vibration signals, the matching relationship between the jet's dominant frequency and the rock's dominant response frequency was calculated. Based on the matching results, the pulse frequency, jet pressure, and feed rate were dynamically adjusted, allowing the jet energy to act more effectively on the rock breaking process, improving energy utilization and crack propagation efficiency. Simultaneously, through joint identification of crack propagation rate and acoustic emission characteristics, differentiated control was achieved for the intrusion stage, crack propagation stage, and stable cutting stage, ensuring that the cutting parameters are always in an optimal state, thereby improving rock fragmentation efficiency and cutting depth. Compared with traditional fixed parameter control methods, cutting efficiency can be improved by 20%–50%.

[0017] Reduced system energy consumption: A frequency matching evaluation model and a multi-objective optimization model are used to evaluate the matching degree between the jet energy input and the rock response state in real time, avoiding energy waste caused by excessive pressure, frequency mismatch, or excessive abrasive supply. Simultaneously, pressure, abrasive flow rate, and feed rate are dynamically adjusted according to the cutting stage, ensuring the system always operates with the minimum energy output required for cutting. Furthermore, feedback closed-loop control promptly corrects control parameters, reducing ineffective and repeated cutting, thereby lowering energy consumption per unit volume of rock. Compared to traditional control methods, unit energy consumption can be reduced by 15%–40%.

[0018] Improving Nozzle Service Life: An online monitoring and compensation mechanism for nozzle wear was established. By monitoring changes in nozzle outlet size in real time, a nozzle wear parameter and wear rate model was built. Dynamic compensation was applied to injection pressure, pulse frequency, and abrasive flow rate to prevent rapid nozzle wear caused by local overload, abnormal erosion, and prolonged high-load operation. Simultaneously, a stable flow field was maintained through valve group control and flow path optimization, reducing the non-uniform erosion effect of abrasive particles on the nozzle inner wall, thereby slowing down the nozzle wear rate and extending nozzle service life. Compared to traditional control methods, nozzle life can be increased by 30%–80%.

[0019] Enhancing adaptability to complex rock formations: By integrating flow field information, rock response information, and equipment status information, a multi-source sensing and collaborative control mechanism is established. This mechanism can automatically adjust cutting parameters based on vibration response, acoustic emission characteristics, crack propagation rate, and cutting effect under different rock formation conditions. When encountering rock formations with varying hardness, different degrees of joint and fracture development, or heterogeneous rock formations, the system can dynamically adjust pulse frequency, nozzle orientation, abrasive flow rate, and feed rate to achieve adaptive switching of cutting strategies. This improves adaptability to complex rock formations and changing working conditions, ensuring the stability and continuity of the cutting process.

[0020] (2) Achieve coordinated control of three fields: flow field, rock response, and equipment status. This breaks through the traditional control system that controls based on a single process parameter. It incorporates jet flow field characteristics, rock damage state, and equipment operating status into a unified control framework, achieving coordinated regulation of frequency matching, wear compensation, stage identification, and feedback optimization, thereby improving the overall control accuracy and intelligence level of the system. Attached Figure Description

[0021] Figure 1 This is a schematic diagram of a high-pressure abrasive waterjet collaborative cutting control system;

[0022] Figure 2 This is a schematic diagram of the execution layer and the multi-source perception layer. Detailed Implementation

[0023] The technical solution of the present invention will be further described below with reference to the accompanying drawings and embodiments.

[0024] A high-pressure abrasive waterjet collaborative cutting control system based on the coupling of flow field feedback and rock response, such as Figure 1 and Figure 2 As shown, the system includes:

[0025] Multi-source sensing layer 1 is used to acquire flow field information, rock response information and equipment status information during the high-pressure abrasive waterjet cutting process.

[0026] The data processing and control core layer 2 is used to process the collected data, extract features, perform frequency matching calculations, make optimization decisions, and output parameters.

[0027] Human-computer interaction and visualization layer 3 is used to realize parameter setting, status monitoring and data output.

[0028] Control instruction output layer 4 is used to generate execution control instructions based on the optimization results.

[0029] Actuator layer 5 is used to adjust the cutting control parameters and complete the cutting process.

[0030] Feedback closed-loop layer 6 is used to provide feedback on the cutting results and system operating status and to correct control parameters.

[0031] Among them, the multi-source perception layer 1 is connected to the data processing and control core layer 2. The data processing and control core layer 2 is connected to the control command output layer 4 and the human-machine interaction and visualization layer 3 respectively. The control command output layer 4 is connected to the actuator layer 5. The feedback closed loop layer 6 forms a closed loop control with the data processing and control core layer 2. The closed loop control relationship between each layer is formed through data flow, control flow and feedback flow.

[0032] The multi-source sensing layer 1 includes: a flow field monitoring module 1.1; a rock response monitoring module 1.2; and an equipment status monitoring module 1.3. The multi-source sensing layer is used to collect jet status, rock response status, and nozzle wear status in real time, and output raw data to the data processing and control core layer.

[0033] The flow field monitoring module 1.1 includes: a pressure sensor 1.1.1, a high-frequency pulsation sensor 1.1.2, a flow meter 1.1.3, a cavitation monitoring sensor 1.1.4, an abrasive concentration sensor 1.1.5, and a temperature sensor 1.1.6; wherein, the pressure sensor is arranged in the high-pressure inlet section; the high-frequency pulsation sensor is arranged on the outer wall of the mixing chamber; the cavitation monitoring sensor is arranged on the outer side of the beam-gathering section; the flow meter is arranged in the high-pressure water supply pipeline and the abrasive conveying pipeline; the cavitation monitoring sensor is arranged on the outer side of the beam-gathering section; the abrasive concentration sensor is arranged in the mixing channel between the outlet of the abrasive mixing chamber and the inlet of the beam-gathering tube; and the temperature sensor is arranged on the outer wall of the mixing chamber.

[0034] The rock response monitoring module 1.2 includes: a vibration sensor 1.2.1, an acoustic emission sensor 1.2.2, a displacement sensor 1.2.3, a crack propagation monitoring device 1.2.4, and a cutting depth detection device 1.2.5.

[0035] Vibration sensors are installed near the cutting area; acoustic emission sensors are arranged on the rock surface; displacement sensors are arranged in the cutting area; crack propagation monitoring devices are arranged outside the rock sample observation surface; and cutting depth detection devices are arranged behind the nozzle movement trajectory.

[0036] The vibration signal A(t), acoustic emission signal E(t), and crack propagation displacement X(t) are used as inputs to the response identification model.

[0037] f r =max[FFT(A(t))]

[0038] R c =dX(t) / dt

[0039] Where: f r Used for frequency matching; R c Reactive crack propagation rate; R c E(t) is used for stage identification; therefore, the vibration signal determines the resonance state, and the crack propagation determines the cutting stage.

[0040] The equipment status monitoring module 1.3 includes: a nozzle wear monitoring device 1.3.1, a rotation angle sensor 1.3.2, a motor current sensor 1.3.3, and a valve position / stroke sensor 1.3.4.

[0041] The nozzle wear monitoring device 1.3.1 measures the nozzle outlet diameter in real time, and inputs the measurement results into the nozzle wear parameter model:

[0042] W=(D e –D0) / D0

[0043] Where: D0 is the initial diameter of the nozzle outlet; D e is the real-time nozzle outlet diameter; W is used to characterize the current wear state of the nozzle and serves as a real-time control input parameter;

[0044] Nozzle wear rate L is defined as:

[0045] L=(W t2 –W t1 ) / Δt

[0046] Among them: W t2 The nozzle wear parameter at the current moment; W t1 The nozzle wear parameters are the parameters from the previous moment; Δt is the sampling time interval; the nozzle wear rate L is used to evaluate the nozzle life status and the trend of cutting performance degradation.

[0047] When L>L c Entering an accelerated wear state; where: L c The controller reduces the cutting feed speed and improves the uniformity of abrasive supply to a preset wear rate threshold.

[0048] Establish a nozzle wear compensation model:

[0049] ΔP=αW+βL

[0050] Δf j =γW+δL

[0051] ΔQ m =μW+νL

[0052] Where: ΔP is the pressure compensation amount; Δf j This is the pulse frequency compensation amount; ΔQ m α represents the abrasive flow rate compensation; α, β, γ, δ, μ, and ν are calibration coefficients.

[0053] The rotation angle sensor 1.3.2 is installed on the turntable of the nozzle rotation / angle change mechanism to collect nozzle rotation angle θ, rotation speed ω and attitude change information in real time, and feeds the collected results back to the control system for nozzle cutting direction control and angle change cutting trajectory correction.

[0054] The motor current sensor 1.3.3 is installed in the power supply circuit of the high-pressure pump drive motor, nozzle rotation drive motor or feed drive motor to collect motor operating current, load changes and operating status information in real time, and to judge the equipment load fluctuation, abnormal wear, blockage or overload status by the current change.

[0055] Valve position / stroke sensor 1.3.4 is installed on abrasive supply valve, electrically controlled pressure regulating valve, flow regulating valve or actuator drive component to detect valve opening, valve core displacement and actuator stroke position in real time and obtain actual execution status parameters.

[0056] The core layer 2 of data processing and control includes: data processing unit 2.1, matching and evaluation unit 2.2, decision-making and optimization unit 2.3, and data storage and management unit 2.4.

[0057] Data processing unit 2.1 is used to preprocess, extract features and characterize the flow field information, rock response information and equipment status information collected by the multi-source sensing layer. This includes filtering and denoising pressure signals, pulsation signals, vibration signals and acoustic emission signals, performing time-frequency analysis and feature extraction, calculating the rate of crack propagation displacement signals, calculating the status of nozzle wear information, and constructing a set of feature parameters for the inverse mapping flow status, rock failure status and equipment operating status as input to matching and evaluation unit 2.2.

[0058] Matching and Evaluation Unit 2.2: Constructing the matching relationship between the jet pulse frequency and the rock response frequency:

[0059] K f =f j / f r

[0060] Where: f j f is the jet pulse frequency; r The rock response frequency is denoted by 0.8; and the value is used to represent the rock response frequency. <K f <1.2 is used as the frequency matching interval; K f <0.8 Increase pulse frequency; K f >1.2, reduce feed rate;

[0061] Decision and Optimization Unit 2.3: Establishing a Multi-Objective Optimization Function

[0062] F = w1E + w2D + w3L

[0063] Where: E is the unit energy consumption; D is the cutting efficiency; L is the nozzle wear rate; w1, w2, and w3 are weighting coefficients, and the weights satisfy (w1+w2+w3=1);

[0064] Generate control vectors based on multi-objective optimization functions:

[0065]

[0066] in: The nozzle rotation angle, This refers to the feed rate.

[0067] The control command output layer 4 includes: a pressure control unit 4.1, an abrasive supply control unit 4.2, a rotation / angle change control unit 4.3, an oscillation / pulse control unit 4.4, a feed motion control unit 4.5, and a valve group and flow path control unit 4.6.

[0068] The pressure control unit 4.1 receives the pressure regulation parameters output by the decision and optimization unit 2.3, generates a pressure control command based on the deviation between the target injection pressure and the real-time pressure, and sends it to the high-pressure pump drive system or the electronically controlled pressure regulating device to adjust the output pressure of the high-pressure pump and realize the dynamic control and stable output of the jet pressure.

[0069] The abrasive supply control unit 4.2 receives the abrasive flow rate and concentration control parameters output by the decision and optimization unit 2.3, generates an abrasive supply control command based on the deviation between the target abrasive supply quantity and the real-time abrasive flow rate, and sends it to the abrasive supply device and abrasive regulating valve to realize the dynamic adjustment of abrasive mass flow rate and concentration.

[0070] The rotation / angle control unit 4.3 receives the nozzle angle parameters and rotation speed parameters output by the decision and optimization unit 2.3, generates attitude control commands based on the deviation between the target attitude and the real-time attitude, and sends them to the rotation drive mechanism or angle actuator to realize nozzle angle adjustment, attitude control and cutting trajectory correction.

[0071] The oscillation / pulse control unit 4.4 is used to receive the pulse frequency, pulse amplitude and duty cycle control parameters output by the decision and optimization unit 2.3, generate oscillation control commands based on the frequency matching results, and send them to the oscillation drive device or pulse generator to realize the dynamic adjustment of jet pulse frequency and pulsation intensity.

[0072] The feed motion control unit 4.5 receives the cutting feed speed and motion trajectory parameters output by the decision and optimization unit 2.3, generates motion control commands based on the deviation between the target feed state and the real-time motion state, and sends them to the feed drive mechanism to realize the adjustment of the feed speed and motion control of the nozzle or cutting platform.

[0073] The valve group and flow path control unit 4.6 is used to receive the flow path switching parameters and valve opening parameters output by the decision and optimization unit 2.3, generate valve group control commands according to the system operating status, and send them to the electric control valve group to realize the switching, distribution and regulation of high pressure water flow, abrasive flow and auxiliary fluid flow path, and ensure the stable operation of the system.

[0074] The actuator layer 5 includes: a high-pressure pump, an electrically controlled valve group, an abrasive supply device, a rotation / angle adjustment mechanism, and a nozzle.

[0075] The pressure control unit 4.1 is connected to the high-pressure pump and is used to generate pressure control commands based on the target pressure parameters to adjust the output pressure of the high-pressure pump.

[0076] The abrasive supply control unit 4.2 is connected to the abrasive supply device and is used to generate abrasive supply control commands based on the target abrasive flow rate and concentration parameters, and to adjust the abrasive supply quantity and supply rate.

[0077] The rotation / angle control unit 4.3 is connected to the rotation / angle mechanism and is used to generate attitude control commands based on the target rotation angle parameters and rotation speed parameters to realize nozzle spatial attitude adjustment and cutting direction control.

[0078] The oscillation / pulse control unit 4.4 is connected to the nozzle and is used to generate oscillation control commands based on the target pulse frequency, pulse amplitude and duty cycle parameters to realize dynamic adjustment of the nozzle pulse jet characteristics.

[0079] The feed motion control unit 4.5 is connected to the cutting execution platform and is used to generate motion control commands based on the target feed speed and motion trajectory parameters to realize the feed motion control of the nozzle or cutting platform.

[0080] The valve assembly and flow path control unit 4.6 is connected to the electrically controlled valve assembly and is used to generate valve assembly control commands based on flow path switching parameters and valve opening parameters to realize the switching, distribution and regulation of high-pressure water flow, abrasive flow and auxiliary fluid flow path;

[0081] The feedback closed-loop layer 6 includes: cutting effect feedback module 6.1 and system status feedback module 6.2.

[0082] The cutting effect feedback module 6.1 is used to receive cutting effect information collected by the cutting depth detection device 1.2.5, crack propagation monitoring device 1.2.4, displacement sensor 1.2.3 and acoustic emission sensor 1.2.2, to obtain cutting depth, cut width, crack propagation length, crack propagation rate and rock fracture state parameters, and to calculate the cutting error based on the deviation between the target cutting parameters and the actual cutting results. The cutting error signal is fed back to the matching and evaluation unit 2.2 and decision and optimization unit 2.3 of the data processing and control core layer 2 for correcting control parameters and optimizing cutting strategies.

[0083] The system status feedback module 6.2 is used to receive system operating status information collected by the flow field monitoring module 1.1 and the equipment status monitoring module 1.3, and to obtain jet pressure, pulsation frequency, abrasive flow rate, abrasive concentration, nozzle wear parameters, nozzle wear rate, nozzle rotation angle, valve opening and equipment load status parameters. The system status information is then fed back to the data processing and control core layer 2 for judging the system operating status, performing wear compensation, frequency matching correction and fault early warning control.

[0084] A control method for high-pressure abrasive waterjet coordinated cutting, comprising the aforementioned high-pressure abrasive waterjet coordinated cutting control system, includes the following steps:

[0085] Step S1: The multi-source sensing layer acquires flow field, rock response, and equipment status information; in this step, the multi-source sensing layer is responsible for simultaneously acquiring jet, rock response, and nozzle equipment status information; the flow field acquisition module obtains the nozzle outlet pressure. oscillating cavity pulsation signal Abrasive flow rate and abrasive concentration The rock response acquisition module acquires rock vibration signals. Acoustic emission signals Crack displacement and cutting depth ; Nozzle wear monitoring device 1.3.1 measures real-time outlet diameter And calculate wear parameters Rotation angle sensor 1.3.2 records the nozzle rotation angle. Rotation speed and cutting feed speed All signals are sampled synchronously using a unified clock, providing a complete input vector for subsequent processing.

[0086] Step S2: The data processing layer performs filtering, feature extraction, and state recognition; in this step, the data processing unit preprocesses the various types of signals acquired. Pressure signal and oscillating pulsation After bandpass filtering (200Hz–10kHz), the vibration signal Harmony emission signal The signal also undergoes appropriate filtering; subsequently, a Fast Fourier Transform (FFT) is performed on the processed signal to extract the main frequency: jet main frequency. and rock response frequency The crack propagation rate is determined by... The calculations are performed; finally, the features are combined to form a state vector. , as input to the matching and evaluation unit.

[0087] Step S3: Establish and evaluate frequency matching relationships; in this step, the matching and evaluation units calculate the frequency matching coefficients. And compare it with the preset locking range (0.8–1.2); based on the current nozzle wear parameters and wear rate Calculate the wear impact factor, and combine it with the real-time cutting depth. Forming a comprehensive evaluation function This is used to determine whether optimization control is triggered; if Not in the locked range, or Exceeding the threshold The system will then enter the control and adjustment phase.

[0088] Step S4: Optimize the algorithm to generate control parameters. The decision-making and optimization unit performs phased optimization control based on the evaluation results of step S3; the phase division is based on the crack propagation rate. Harmony emission characteristic parameters The stage is categorized as: initial intrusion stage, crack propagation stage, or stable cutting stage; the control objectives differ for each stage: increasing pressure in the initial stage. And reduce the feed rate Increase pulse frequency during crack propagation stage And optimize nozzle rotation angle During the stable phase, energy consumption should be reduced as a priority. And maintain stable cutting; optimize the results to generate control vectors. , as the input to the control output layer.

[0089] Step S5: The control command output layer controls the actuator; the control output layer receives the optimized control vector. Each instruction is mapped to a specific actuator: the high-pressure pump regulates the pressure. Abrasive valve for flow regulation 1. Adjusting the pulse frequency of the oscillation driver Servo mechanism adjusts nozzle angle Adjusting the feed platform speed The actuator layer precisely adjusts the spray state according to the control vector to achieve real-time cutting operation.

[0090] Step S6: The feedback layer collects the cutting results and corrects the parameters; during execution, the feedback closed-loop layer monitors the cutting depth in real time. kerf width and nozzle wear rate By calculating the cutting error , For the target cutting depth, This represents the actual cutting depth, excluding cutting error. If the error exceeds the preset tolerance (e.g., 5%), the system will report back to the data processing and control core layer to recalculate frequency matching, wear compensation, and stage control optimization to ensure cutting quality and system stability.

[0091] Step S7: By cyclically executing steps S1–S6, the system forms a continuous closed-loop control. Each iteration uses the latest collected flow field, rock response, and equipment status data for calculation, enabling frequency locking, wear compensation, and stage control strategies to work together to achieve high-efficiency, high-stability, and long-life high-pressure abrasive waterjet cutting control.

[0092] Finally, it should be noted that the above embodiments are only used to illustrate the technical solutions of the present invention and are not intended to limit it. Although the present invention has been described in detail with reference to preferred embodiments, those skilled in the art should understand that modifications or equivalent substitutions can be made to the technical solutions of the present invention without departing from the spirit and scope of the technical solutions of the present invention, and all such modifications or substitutions should be covered within the scope of the claims of the present invention.

Claims

1. A high-pressure abrasive waterjet collaborative cutting control system, characterized in that, The system includes: Multi-source sensing layer (1) is used to acquire flow field information, rock response information and equipment status information during high-pressure abrasive waterjet cutting process; The core layer of data processing and control (2) is used to process the collected data, extract features, calculate frequency matching, make optimization decisions and output parameters; The human-computer interaction and visualization layer (3) is used to realize parameter setting, status monitoring and data output; The control instruction output layer (4) is used to generate execution control instructions based on the optimization results; The actuator layer (5) is used to adjust the cutting control parameters and complete the cutting process; The feedback closed-loop layer (6) is used to provide feedback on the cutting results and system operating status and to correct the control parameters; Among them, the multi-source perception layer (1) is connected to the data processing and control core layer (2), the data processing and control core layer (2) is connected to the control command output layer (4) and the human-machine interaction and visualization layer (3) respectively, the control command output layer (4) is connected to the actuator layer (5), and the feedback closed loop layer (6) forms a closed loop control with the data processing and control core layer (2).

2. The high-pressure abrasive waterjet coordinated cutting control system according to claim 1, characterized in that, The multi-source sensing layer (1) includes: a flow field monitoring module (1.1); a rock response monitoring module (1.2); and an equipment status monitoring module (1.3). The multi-source sensing layer is used to collect jet status, rock response status and nozzle wear status in real time, and output raw data to the data processing and control core layer.

3. The high-pressure abrasive waterjet coordinated cutting control system according to claim 2, characterized in that, The flow field monitoring module (1.1) includes: a pressure sensor (1.1.1), a high-frequency pulsation sensor (1.1.2), a flow meter (1.1.3), a cavitation monitoring sensor (1.1.4), an abrasive concentration sensor (1.1.5), and a temperature sensor (1.1.6); wherein, the pressure sensor is arranged in the high-pressure inlet section; the high-frequency pulsation sensor is arranged on the outer wall of the mixing chamber; the flow meter is arranged on the high-pressure water supply pipeline and the abrasive conveying pipeline; the cavitation monitoring sensor is arranged on the outside of the beam-gathering section; the abrasive concentration sensor is arranged in the mixing channel between the outlet of the abrasive mixing chamber and the inlet of the beam-gathering tube; and the temperature sensor is arranged on the outer wall of the mixing chamber.

4. The high-pressure abrasive waterjet coordinated cutting control system according to claim 2, characterized in that, The rock response monitoring module (1.2) includes: a vibration sensor (1.2.1), an acoustic emission sensor (1.2.2), a displacement sensor (1.2.3), a crack propagation monitoring device (1.2.4), and a cutting depth detection device (1.2.5). Vibration sensors are installed near the cutting area; acoustic emission sensors are arranged on the rock surface; displacement sensors are arranged in the cutting area; crack propagation monitoring devices are arranged outside the rock sample observation surface; and cutting depth detection devices are arranged behind the nozzle movement trajectory. The vibration signal A(t), acoustic emission signal E(t), and crack propagation displacement X(t) are used as inputs to the response identification model. f r =max[FFT(A(t))] R c =dX(t) / dt Where: f r Used for frequency matching; R c Reactive crack propagation rate; R c E(t) is used for stage identification; therefore, the vibration signal determines the resonance state, and the crack propagation determines the cutting stage.

5. A high-pressure abrasive waterjet collaborative cutting control system according to claim 2, characterized in that, The equipment status monitoring module (1.3) includes: a nozzle wear monitoring device (1.3.1), a rotation angle sensor (1.3.2), a motor current sensor (1.3.3), and a valve position / stroke sensor (1.3.4). The nozzle wear monitoring device (1.3.1) measures the nozzle outlet diameter in real time, and the measurement results are input into the nozzle wear parameter model. W=(D e –D0) / D0 Where: D0 is the initial diameter of the nozzle outlet; D e is the real-time nozzle outlet diameter; W is used to characterize the current wear state of the nozzle and serves as a real-time control input parameter; Nozzle wear rate L is defined as: L=(W t2 –W t1 ) / Δt Among them: W t2 The nozzle wear parameter at the current moment; W t1 The nozzle wear parameters are the parameters from the previous moment; Δt is the sampling time interval; the nozzle wear rate L is used to evaluate the nozzle life status and the trend of cutting performance degradation. When L>L c Entering an accelerated wear state; where: L c The controller reduces the cutting feed speed and improves the uniformity of abrasive supply to a preset wear rate threshold. Establish a nozzle wear compensation model: ΔP=αW+βL Δf j =γW+δL ΔQ m =μW+νL Where: ΔP is the pressure compensation amount; Δf j This is the pulse frequency compensation amount; ΔQ m α represents the abrasive flow rate compensation; α, β, γ, δ, μ, and ν are calibration coefficients. The rotation angle sensor (1.3.2) is installed on the turntable of the nozzle rotation / angle change mechanism to collect nozzle rotation angle θ, rotation speed ω and attitude change information in real time, and feed the collection results back to the control system for nozzle cutting direction control and angle change cutting trajectory correction. The motor current sensor (1.3.3) is installed in the power supply circuit of the high-pressure pump drive motor, nozzle rotation drive motor or feed drive motor to collect motor operating current, load changes and operating status information in real time, and to judge the equipment load fluctuation, abnormal wear, blockage or overload status by the current change; The valve position / stroke sensor (1.3.4) is installed on the abrasive supply valve, the electrically controlled pressure regulating valve, the flow regulating valve or the actuator drive component to detect the valve opening, valve core displacement and actuator stroke position in real time and obtain the actual execution status parameters.

6. The high-pressure abrasive waterjet collaborative cutting control system according to claim 1, characterized in that, The core layer of data processing and control (2) includes: a data processing unit (2.1), a matching and evaluation unit (2.2), a decision-making and optimization unit (2.3), and a data storage and management unit (2.4). The data processing unit (2.1) is used to preprocess, extract features and characterize the flow field information, rock response information and equipment status information collected by the multi-source sensing layer. This includes filtering and noise reduction, time-frequency analysis and feature extraction of pressure signals, pulsation signals, vibration signals and acoustic emission signals, calculating the rate of crack propagation displacement signals, calculating the status of nozzle wear information, and constructing a set of feature parameters for the inverse mapping flow status, rock failure status and equipment operation status as input to the matching and evaluation unit (2.2). The matching and evaluation unit (2.2) constructs the matching relationship between the jet pulse frequency and the rock response frequency: K f =f j / f r Where: f j f is the jet pulse frequency; r The rock response frequency is denoted by 0.

8. <K f <1.2 is used as the frequency matching interval; K f <0.8 Increase pulse frequency; K f >1.2, reduce feed rate; The decision-making and optimization unit (2.3) establishes a multi-objective optimization function: F = w1E + w2D + w3L Where: E is the unit energy consumption; D is the cutting efficiency; L is the nozzle wear rate; w1, w2, and w3 are weighting coefficients, and the weights satisfy w1+w2+w3=1; Generate control vectors based on multi-objective optimization functions: in: The nozzle rotation angle, This refers to the feed rate.

7. The high-pressure abrasive waterjet collaborative cutting control system according to claim 1, characterized in that, The control command output layer (4) includes: a pressure control unit (4.1), an abrasive supply control unit (4.2), a rotation / angle control unit (4.3), an oscillation / pulse control unit (4.4), a feed motion control unit (4.5), and a valve group and flow path control unit (4.6). The pressure control unit (4.1) is used to receive the pressure regulation parameters output by the decision and optimization unit (2.3), generate pressure control commands based on the deviation between the target injection pressure and the real-time pressure, and send them to the high-pressure pump drive system or the electronic pressure regulating device to adjust the output pressure of the high-pressure pump and realize the dynamic control and stable output of the jet pressure. The abrasive supply control unit (4.2) is used to receive the abrasive flow rate and concentration control parameters output by the decision and optimization unit (2.3), generate abrasive supply control commands based on the deviation between the target abrasive supply quantity and the real-time abrasive flow rate, and send them to the abrasive supply device and abrasive regulating valve to realize the dynamic adjustment of abrasive mass flow rate and concentration. The rotation / angle control unit (4.3) is used to receive the nozzle angle parameters and rotation speed parameters output by the decision and optimization unit (2.3), generate attitude control commands based on the deviation between the target attitude and the real-time attitude, and send them to the rotation drive mechanism or angle actuator to realize nozzle angle adjustment, attitude control and cutting trajectory correction. The oscillation / pulse control unit (4.4) is used to receive the pulse frequency, pulse amplitude and duty cycle control parameters output by the decision and optimization unit (2.3), generate oscillation control commands according to the frequency matching results, and send them to the oscillation drive device or pulse generator to realize the dynamic adjustment of jet pulse frequency and pulsation intensity. The feed motion control unit (4.5) is used to receive the cutting feed speed and motion trajectory parameters output by the decision and optimization unit (2.3), generate motion control commands based on the deviation between the target feed state and the real-time motion state, and send them to the feed drive mechanism to realize the adjustment of the feed speed and motion control of the nozzle or cutting platform. The valve group and flow path control unit (4.6) is used to receive the flow path switching parameters and valve opening parameters output by the decision and optimization unit (2.3), generate valve group control commands according to the system operating status, and send them to the electric control valve group to realize the switching, distribution and adjustment of high pressure water flow, abrasive flow and auxiliary fluid flow path, and ensure the stable operation of the system.

8. The high-pressure abrasive waterjet collaborative cutting control system according to claim 1, characterized in that, The actuator layer (5) includes: a high-pressure pump, an electrically controlled valve group, an abrasive supply device, a rotation / angle-changing mechanism, and a nozzle; The pressure control unit (4.1) is connected to the high-pressure pump and is used to generate pressure control commands based on the target pressure parameters to adjust the output pressure of the high-pressure pump; The abrasive supply control unit (4.2) is connected to the abrasive supply device and is used to generate abrasive supply control commands based on the target abrasive flow rate and concentration parameters, and to adjust the abrasive supply quantity and supply rate. The rotation / angle control unit (4.3) is connected to the rotation / angle mechanism and is used to generate attitude control commands based on the target rotation angle parameters and rotation speed parameters to realize nozzle spatial attitude adjustment and cutting direction control; The oscillation / pulse control unit (4.4) is connected to the nozzle and is used to generate oscillation control commands based on the target pulse frequency, pulse amplitude and duty cycle parameters to realize dynamic adjustment of the nozzle pulse jet characteristics; The feed motion control unit (4.5) is connected to the cutting execution platform and is used to generate motion control commands based on the target feed speed and motion trajectory parameters to realize the feed motion control of the nozzle or cutting platform; The valve assembly and flow path control unit (4.6) is connected to the electrically controlled valve assembly and is used to generate valve assembly control commands based on the flow path switching parameters and valve opening parameters to realize the switching, distribution and regulation of high-pressure water flow, abrasive flow and auxiliary fluid flow path.

9. A high-pressure abrasive waterjet collaborative cutting control system according to claim 8, characterized in that, The feedback closed-loop layer (6) includes: a cutting effect feedback module (6.1) and a system status feedback module (6.2). The cutting effect feedback module (6.1) is used to receive the cutting effect information collected by the cutting depth detection device (1.2.5), crack propagation monitoring device (1.2.4), displacement sensor (1.2.3) and acoustic emission sensor (1.2.2), to obtain the cutting depth, cut width, crack propagation length, crack propagation rate and rock fracture state parameters, and to calculate the cutting error based on the deviation between the target cutting parameters and the actual cutting results. The cutting error signal is fed back to the matching and evaluation unit (2.2) and decision and optimization unit (2.3) of the data processing and control core layer (2) for correcting the control parameters and optimizing the cutting strategy. The system status feedback module (6.2) is used to receive system operating status information collected by the flow field monitoring module (1.1) and the equipment status monitoring module (1.3), obtain jet pressure, pulsation frequency, abrasive flow rate, abrasive concentration, nozzle wear parameters, nozzle wear rate, nozzle rotation angle, valve opening and equipment load status parameters, and feed the system status information back to the data processing and control core layer (2) for judging the system operating status, performing wear compensation, frequency matching correction and fault early warning control.

10. A method for controlling high-pressure abrasive waterjet coordinated cutting, characterized in that, The control method employs the high-pressure abrasive waterjet collaborative cutting control system described in any one of claims 1-9; the control method includes the following steps: Step S1: The multi-source sensing layer acquires flow field, rock response, and equipment status information; in this step, the multi-source sensing layer is responsible for simultaneously acquiring jet, rock response, and nozzle equipment status information; the flow field acquisition module obtains the nozzle outlet pressure. oscillating cavity pulsation signal Abrasive flow rate and abrasive concentration ; Rock response acquisition module acquires rock vibration signals Acoustic emission signals Crack displacement and cutting depth Nozzle wear monitoring device (1.3.1) measures real-time outlet diameter. And calculate wear parameters The rotation angle sensor (1.3.2) records the nozzle rotation angle. Rotation speed and cutting feed speed All signals are sampled synchronously using a unified clock to provide a complete input vector for subsequent processing. Step S2: The data processing layer performs filtering, feature extraction, and state recognition; in this step, the data processing unit preprocesses the various acquired signals; pressure signal and oscillating pulsation After bandpass filtering (200Hz–10kHz), the vibration signal Harmony emission signal The signal also undergoes appropriate filtering; subsequently, a Fast Fourier Transform (FFT) is performed on the processed signal to extract the main frequency: the jet main frequency. and rock response frequency The crack propagation rate is determined by The calculations are performed; finally, the features are combined to form a state vector. , as input to the matching and evaluation unit; Step S3: Establish and evaluate frequency matching relationships; in this step, the matching and evaluation units calculate the frequency matching coefficients. And compare it with the preset locking range; based on the current nozzle wear parameters and wear rate Calculate the wear impact factor, and combine it with the real-time cutting depth. Forming a comprehensive evaluation function This is used to determine whether optimization control is triggered; if Not in the locked range, or Exceeding the threshold The system will then enter the control and adjustment phase; Step S4: Optimize the algorithm to generate control parameters; The decision-making and optimization unit performs phased optimization control based on the evaluation results of step S3; Stage division is based on crack propagation rate Harmony emission characteristic parameters It can be determined as: initial intrusion stage, crack propagation stage, or stable cutting stage; The control objectives differ at different stages: the initial stage increases pressure. And reduce the feed rate Increase pulse frequency during crack propagation stage And optimize nozzle rotation angle During the stable phase, energy consumption should be reduced as a priority. And maintain stable cutting; optimize the results to generate control vectors. , as the input to the control output layer; Step S5: The control command output layer controls the actuator; the control output layer receives the optimized control vector. Each instruction is mapped to a specific actuator: the high-pressure pump regulates the pressure. Abrasive valve for flow regulation 1. Adjusting the pulse frequency of the oscillation driver Servo mechanism adjusts nozzle angle Adjusting the feed platform speed The actuator layer precisely adjusts the injection state according to the control vector to achieve real-time cutting operation. Step S6: The feedback layer collects the cutting results and corrects the parameters; During execution, the feedback closed-loop layer monitors the cutting depth in real time. kerf width and nozzle wear rate By calculating the cutting error , For the target cutting depth, This represents the actual cutting depth, excluding cutting error. If the preset tolerance is exceeded, the system will feed back to the data processing and control core layer to recalculate the frequency matching, wear compensation and stage control optimization to ensure cutting quality and system stability. Step S7: By cyclically executing steps S1–S6, the system forms a continuous closed-loop control. Each iteration uses the latest collected flow field, rock response, and equipment status data for calculation, enabling frequency locking, wear compensation, and stage control strategies to work together to achieve high-efficiency, high-stability, and long-life high-pressure abrasive waterjet cutting control.

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